Apparatus for making tile panels



Dec. 22, 1959 J. v. FITZGERALD 2,917,801

Filed Nov. 29, 1954 INVENTOR. Joy/v V. F/TZGERALD Dec. 22, 1959 .1. v. FITZGERALD 2,917,801

APPARATUS F OR MAKING TILE PANELS Filed Nov. 29, 1954 3 Sheets-Sheet 2 INVENTOR.

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flrromvir Dec. 22, 1959 J. v. FITZGERALD 2,917,801

APPARATUS FOR MAKING TILE PANELS Filed Nov. 29, 1954 3 Sheets-Sheet 3 x v-Hm; 17 15171;

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Jamv MHrzam/aw 2% f/ ZL United States Patent APPARATUS FOR MAKING TILE PANELS John V. Fitzgerald, Metuchen, N.J., assignor to Tile Council of America, Incorporated, a corporation of New York Application November 29, 1954, Serial No. 471,749

3 Claims. (Cl. 25--1) The present invention relates to panels constructed of a plurality of tiles and more particularly to apparatus suitable for mass production of multiple tile panels.

The employment of prefabricated multiple tile panels may offer a number of advantages which arenot to be obtained by the construction of tile walls or panels at their permanent installation. The panels constructed with maximum tolerances and in accordance with mass production techniques may be made more uniform and thus provide a more pleasing appearance. Panels cut to predetermined sizes may be more quickly installed in a wide variety of installations. Prefabricated panels may be made more impervious to water or vapor.

A primary object of this invention is to provide an improved apparatus for making tile panels.

It is another object of this invention to provide apparatus for manufacturing panels consisting of a plurality of tiles wherein the panels are more uniform than can normally be done at a permanent installation of the tile panel.

It is still another object of this invention to provide increased use of tile by reducing cost of installation of tile.

According to this invention there is provided apparatus for the construction of multiple tile panels consisting of a rigid support member adapted to support a plurality of tiles on its upper surface in such a manner that the tiles are positioned edge to edge finished surface downward and spaced from each other to form grooves between the tiles. A flexible element distributed on the rigid support member under the grooves formed between the tiles is employed to seal the bottom of the grooves to enable the use of a fluid bonding agent. Means are provided for pressing the tiles and the flexible element together so as to cause the flexible element to provide a convex surface in the bottom of each of the grooves between the tiles.

Other and incidental objects of the invention will become apparent after a reading of the following specifications and aninspection of the accompanying drawings wherein: V

Figure 1 illustrates the invention in one of its forms.

Figure 2 illustrates in more detail a portion of the machine shown in Figure 1. There is also shown in Figure 2 a series of heat lamps which may be employed to hasten the setting of the bonding agent.

Figure 3 shows detail in perspective of one form of this invention.

Figure 4 shows detail concerning another form of this invention.

Figure. 5 shows still another form of this invention wherein there is employed a pneumatic flexible element .for both sealing the bottom of the grooves between the tiles and forapplying pressure to the tile.

Figure 6 shnws still another form of this invention Figures 9, 10 and 11 show additional forms whichthe flexible element between the tiles and the rigid support member may take.

Figure 12 shows still another form of this invention 1 wherein there is employed a thin layer of flexible material over a series of rods.

Figure 13 illustrates details concerning. a lever which is employed to raise the upper grillwork shown' in Figure 1 to permit the insertion of the plurality of tiles.

Throughout the various figures of the drawing the same number will be employed to designate thesame element.

Turning now in more detail to Figure 1, there is shown one form of this invention wherein a table or other rigid support member 11 is adapted to receive a rigid support member 13 upon which there has been placed a plurality of tiles 15. The tiles. 15 are placed edge to edge and spaced sufiiciently toprovide a uniform groove 17 between each of the tiles 15. The tiles are placed with their finished surface downward on a flexible element 19, such as rubber or foam rubber. v n

The assembly of tiles 15 is placed under the grillwork 21 such that one of the edgewise positioned metal bars 23 is located over each row of thetiles 115. The edgewise positioned metal bars 23 are supported at theirends by angle iron 25. A plurality of dish shaped elements" 27 are fastened to the bottom of each of the edgewise positioned bars 23 in such a manner that one of the" dish shaped members 27 is centered on each of the tiles.

15 when grill member 21 is lowered to apply pressure to the tiles 15.

The grill shaped member 21 is clamped down to apply pressure to the tiles by wing nuts 29 which are located.

on both sides of the grill 21; Handles iil also located on both sides of the grill 21 are employed to raise the grill 21 off from the tiles 15 when the wing nuts 21 are loosened- It will be understood that the grill 21 mus-t be raised at the time the tiles 15 are inserted or removed from the machine. i i

The bolts 33 upon which the wing nuts 29 are adapted to be placed extend from angle iron 35 on each. side of the machine and are made fast to the angle iron 35 in order that they will extend upward and act as a guidewhen the grill 21 is being raised or lowered.

Table 11 may be extended to the left to provide a plat form to support the member 13 upon which the tiles 15 may be put in their proper position and design before the assembly of the base13 and tiles 15 is pushed under the grill 21.

Apparatus suitable for the manufacture of panels of standard 4 by 4 by ceramic tile and cons structed in accordance with the teachings of this invention q in the form shown in Figure 1 may have the following. dimensions. Table 11 measures 5'7" wide by 8' long.

Edgewise positioned bars 23 measure 2" by.

tive purposes only and are not intended vention.-

tween tiles for the tile bonding agent can be made.

Turning now to Figure 2; there is shown details concerning the. rigid base member 13, flexible member 19, tiles 15 and the dish shaped members 27 as shown in Figure 1.

The rigid base member 13 may, for example, be a sheet. of=plywood upon-which ismounted a flexible element 19 with a suitable adhesive to prevent the flexible element 19 from shifting its position on the rigid base member 13.

The flexible element 19 is distributed over the surface of. the rigid base member 13 in such a manner that it willlie. under the grooves 17 between the-tiles 15.

A cleavage or release membrane 36 islocated between the: tiles 15 and the flexible element 19. The-cleavage membranefifiis employed to prevent the liquid agent which is poured into grooves 17 from sticking to the-flexible element 19. The cleavage membrane 36 may be made of polyethylene .0025 thick.

In the form of the invention shown inFigures 2 and'3 the flexible element, 19 takes a grill-like form Whose openings 37 are'positioned under eachof the tiles IS.

In the form of thelinvention shown-in-Fig-ures 2 and 3 the flexible element 19' is cut out under the center of each tile in order to cause the flexible element 19 to bulge upward into the groove 17 when pressure is appliedto the tiles 15. It will be seen that as the flexible element 19 bulges upwardly into the groove 17 there will be formed aconvex surface in the bottomof-th'e-groove 17. Theinto the groove when the flexible element 19 is subjected V to pressure by the tile 15 provides for an attractive concave surface to'the bonding agent on the finished surface of the panel. It will be remembered that the finished surface of the tiles 15 is downward in Figures 2 and 3.

In Figure 2 there is shown heat lamps 39 which are distributed over the whole surface of the machine to accelerate the setting of the bonding agent poured into grooves .17.

In Figure 3 there is illustrated a circular dish shapedelernent 27 centered over each tile 15 to apply pressure uniformly to thetile 15.

InFigure4 there is shown asquare dish shaped member 27 attached to bar 23' for the purpose of distributing thepressure evenly-on the tile 15.

A practical embodiment of the form of the invention shown in Figure 2 employs 3" washers welded to the bottom of. edgewise positioned bars 23 at the location of each of the tiles 15. The invention in the form shown in Figure 2 hasoperated successfully by the employment of /z sponge rubber, softness grade, as the flexible element 19. A suitable size for the cut outs 37 has been found to be- 3" square when ceramic measuring 4 by 47 by was employed.

FigureSshows another form of this invention wherein there is provided a flexible element in the form of a pneumatic tube 41. The pneumatic tube 41 may be expanded by use of air or liquid inserted into the pneumatic tube 41 through a valve stem-43. It will be understood that in the form of the invention shown in Figure 5 the upper grillwork 45 may be positioned in a fixed relation with the supporting table beneath the rigid base member13. A cleavage membrane 36 is employed to prevent the bonding agent in grooves '17 from sticking to the pneumatic flexible element 4 In the.form of the invention shown in FigureS theassen-ably of the rigid base member-13, the flexible element 41, the leavage membrane36, and the-tiles 15 maylall' be-assembled-out frpmunderthegrill wor k 45 and slid into position in the machine and under the grill work 45 before inflation of the pneumatic flexible element 41. When in position the pneumatic flexible element 41 is inflated in order to force the tiles 15 up against the grillwork 4.5. The bonding agent is then poured into the grooves 17 and allowed to set. The pneumatic flexible element 41 is deflated when thebonding agent in grooves 17 has set and the assembly is pulled out of the machine. The finished tile panel may then be easily removedfrom the assembly which is then ready to receiveanother groupv of tiles 15 for the fabrication of another'tile panel.

Figure 6 shows another form of this invention wherein there is employed a series of rigid rods 47 under the flexible element 19 which in this form ofthe invention may consist of a solid layer ofifl'exible material such as sponge rubber. The rigid rods 47 are positioned under all of the grooves 17 between the tiles 15. It will be understood that the rods 47 extend crosswise to form a grill or screen-like pattern, The purpose of, the rods 47 is to cause a bulge of the flexible element 19'into the bottom part of all of the grooves 17. p

In the form of the invention shown in Figure 6' upper grill work 49 includes flexible members 51 on the contact points of the grill work 49 with the tiles 15. Elements 51 may, for example, take the form of Ms hard rubber cushions. Rods 47, may, for example, be ii f' diameter metal haif-rounds to force the /2" foam rubber I19 tightly against the edges of the tiles 15.

Figure 7 shows still another; form of this invention wherein there is employed individual hydraulic pistons 53 for applying pressure to the top of ,each of the tiles 15. In this manner equal pressure may be conveniently applied to each of the tiles 15. The hydraulic pistons 53 may be energized by forcing liquid into" the common supply chamber 55.

Figure 8 illustrates still another-form of this invention wherein there is-provided steps 57 inthe form of extensions of the rigid base member 59 to'provide a uniform limit to the downward movement of the tiles 15 when subjected to pressure by the grill work- 61. In order to provide for the necessary resilience in the members clamping the tiles 15 flexible elements 63 have been inserted in the griil 61.

It will be understood that with the employment of the stops 57 a tile panel may be-fabricated which has an ex tremely accurate finished surface.

Figure 9 illustrates still another'form of-this invention wherein individual weightsEdareempleyed to'acquire uniform pressure against eachofthetiles 15. In the form of the invention shown in- Figure 9 tllere isillustrated a split rubber tubing 'icovering a-half-round'tii).

The combination of. the-split n1b'ber tubii'ig67 and"the-" half-round69"extendunderall of the: grooves 17 in order to provide aconvex surface in. thebottom"of'the grooves A Figure 10 illustrates a form of the invention employing soft rubber rods or tubes-71'asflexihie elements. When soft rubber tubes 71 are. employed little or no pressure on the top of, the tiles. 15:.is acquired to pro vide for a convex surface in the bottom of grooves i7.

Figure 11 vshows the useofsplit flexible. tubing 7311s the required flexible element.

Figure 12 illustratesa form of:the' invention -rwhercins there is provided a seriesof rods 75 coV-eredby aithin' sheet of flexible material'77. The "material 77imay, for,

example, consist ofa-thin sheet of /s-" foatfnrubbeu-- In the forms of the invention shown in Figures 8,19; 10, 11, and 12 it will be seen that no cleavage membrane such as illustrated'in the other forms of the invention is employed. In order to prevent the bonding agent from adhering to the flexible elements the flexible elements may be coated with silicone to provide for the' releasenf' the bonding agent. w I

the

order to prevent a feather edge of the bonding agent on the surface of the tile adjacent to the edges of the tile by capillary action of the bonding agent a silicon oil or a silicon emulsion may be employed to coat the surface of the tile near the edges of the tile in contact with the cleavage membrane or flexible element. Other agents than silicone may be used providing they are incompatible with the bonding agent in order that they will prevent capillary action of the bonding agent.

Figure 13 illustrates an end view of the levers 31 more clearly shown in Figure l. The fulcrum 79 of the lever 31 may be fixed to the angle iron 35 of Figure 1. By pressing downward on the handle 81 the point 83 will be pushed upward to lift the grill 21.

Apparatus constructed in accordance with the teachings of this invention is suitable for the fabrication of ceramic tile panels as shown and described in my co-pending application entitled Ceramic Tile Panels and Structural Members, Serial No. 471,748, concurrently filed.

Although any suitable bonding agent may be employed in the grooves 17 an improved bonding agent is described in my co-pending application entitled Dry Mortar Mix Comprising Portland Cement and Polyvinyl Acetate, Serial No. 471,910, concurrently filled. The application referred to immediately above teaches the use of Portland cement and polyvinyl acetate in the ratio of about one hundred parts by Weight of the cement and up to fifty parts by weight of the polyvinyl acetate. A stearate and powdered aluminum as well as a fungicide may be added to the mortar mix suggested immediately above.

Having thus described the invention What is claimed is:

1. Apparatus for making tile panels comprising the combination of a rigid support member, said rigid support member adapted to receive a plurality of tiles positioned edge to edge and spaced from each other forming grooves between tiles, a flexible member having a grill-like form, said flexible member distributed on said rigid support member under the grooves between said tiles and forming a convex surface at the bottom of the grooves between the tiles, means for pressing said tiles and said flexible member together, means for filling the grooves between the tiles with a tile bonding agent, and wherein said pressure applying means consists of means for expanding said flexible member and there is provided a rigid member clamping said tile and said rigid support member.

2. Apparatus for assembling glazed tile panels comprising the combination of a support member having a flexible surface element, a plurality of tiles positioned edge to edge, glazed side downward on. the flexible surface element of said support member, said flexible surface element having greatest uncompressed thickness un der the space between the edges of said tile and with a space between said tiles, means for compressing said flexible surface element with said tiles, means for filling the space between the edges of said tile with. a bonding agent while said flexible surface element is in a compressed condition, and wherein there is provided a compression limiting member under each tile, said compression limiting member consisting of rigid members extending from said support member by an amount less than the thick ness of said flexible surface element when said flexible surface element is not compressed.

3. The invention as set forth in claim 2 and wherein said compressing means includes a flexible member.

References Cited in the file of this patent UNITED STATES PATENTS 1,082,231 Nale Dec. 23, 1913 2,178,535 Willson Oct. 31, 1939 2,266,510 Pottinger Dec. 16, 1941 2,572,580 Almroth et al. Oct. 23, 1951 2,613,423 Davis Oct. 14, 1952 2,654,625 Ensign et al. Oct. 13, 1953 2,654,925 Ensign Oct. 13, 1953 FOREIGN PATENTS 577,677 Great Britain May 28, 1946 

